Segmented spiral staircase and kit for its construction

ABSTRACT

A segmented spiral staircase and kit for its construction has a plurality of laterally extending step segments. Each step segment has a step surface with an inboard, donut-shaped end section and lower downwardly extending support members. Each step segment also has an upstanding baluster rail member connected by screws to the outboard end of the step surface. The step segments are each rotatably mounted, at their respective inboard end sections, in offset fashion through a vertically standing support post. The baluster rail members of the step segments are configured to be aligned adjacent to each other and are connected one to the other by screws. Spacer sleeves separate each of the step segments, whose lower support members are positioned against the vertical surfaces of the sleeves. Alternate stacking of the sleeves and step segments and connection of the baluster rail members produces a sturdy staircase structure which also includes an upper landing member. The relatively lightweight nature of the components of the kit make assembly easy and, by simply removing the screw connections between baluster rail members, a step segment or entire section of the staircase made up of several step segments can be rotated around the vertical support post to alter the configuration of the staircase.

RELATED APPLICATION

This application is a continuation-in-part of application Ser. No.11/169,548, filed on Jun. 29, 2005.

BACKGROUND OF THE INVENTION

Spiral staircases are both functional and decorative structures whichallow for access between floors of residential and commercial spaces.Spiral staircases also are favored because of the smaller amount ofspace they require, as opposed to straight staircases. There are manyoccasions in which there simply is insufficient room in a building spacefor a straight stairway, and no other means to interconnect two levels,except by using a spiral staircase.

However, although a spiral staircase occupies a relatively small area,it presents difficulties in construction. For instance, there arelogistically problems with the use of prefabricated spiral staircaseunits, both in safely packing and protecting them for shipment. Thecarriage and delivery of prefabricated staircases also may be cumbersomeand difficult, especially in getting the staircases into the rooms wherethey are to be installed. In fact, most standard spiral staircases willnot fit into many smaller rooms, resulting in the need to ordercustomized units, with the resulting increase in price. In addition,there are usually installation problems in properly fitting spiralstaircases between floors.

To overcome these problems, there have been attempts to provide spiralstaircase installations with components which can be assembled on thejob. Some examples of these are found in U.S. Pat. Nos. 1,361,918,3,740,906, 3,964,222, 4,128,976, 4,850,164 and 5,557,893.

However, these and similar spiral staircase installations result instructures which are often not very sturdy. They may be unstable andwobbly, and even unsafe. In addition, most prior assembled spiralstaircases are complicated and difficult to put together. They have manydifferent component parts, requiring connection by bolts, screws, nails,rivets, or even welding or brazing.

Another handicap of existing spiral staircases is that they are designedto be permanent installations. If there is a need to temporarily changethe configuration of the staircase, for instance to transport largepieces of furniture up the staircase, the permanently installed curvednature of the staircase makes this most difficult.

SUMMARY OF THE INVENTION

It is thus the object of the present invention to overcome thelimitations and disadvantages of prior spiral staircases and spiralstaircase assemblies and kits.

It is an object of the present invention to provide a spiral staircasekit which, when its components are assembled, results in a spiralstaircase which is steady, sturdy, and safe for use.

It is another object of the present invention to provide a spiralstaircase and spiral staircase kit which comprises relatively fewdifferent components.

It is still another object of the present invention to provide a spiralstaircase and spiral staircase kit with components which are inexpensiveand easy to manufacture, lightweight, and simple to assemble.

It is a further object of the present invention to provide a spiralstaircase and spiral staircase kit in which all components are easilyhandled for assembly and installation of the complete spiral staircaseunit.

It is still a further object of the present invention to provide aspiral staircase which, in its disassembled state, is easilytransportable to the installation site.

It is another object of the present invention to provide a spiralstaircase kit which requires minimal use of screws, nails, bolts, rivetsor other connecting elements.

It is a further object of the present invention to provide a spiralstaircase and spiral staircase kit whose components can be configuredand manufactured with a plurality of attractive design options.

It is another object of the present invention to provide a spiralstaircase kit which allows installation of the staircase between floorswhere space is limited.

It is still another object of the present invention to provide a spiralstaircase kit which results in the assembly of a spiral staircase whichcan be configured and customized for any space.

It is a further object of the present invention to provide a spiralstaircase kit which results in a spiral staircase which has a pluralityof step segments which are readily disconnected to conveniently alterthe configuration of the staircase.

These and other objects are accomplished by the present invention, asegmented spiral staircase and kit for its construction having aplurality of laterally extending step segments. Each step segment has astep surface with an inboard, donut-shaped end section and lowerdownwardly extending support members. Each step segment also has anupstanding baluster rail member connected by screws to the outboard endof the step surface. The step segments are each rotatably mounted, attheir respective inboard end sections, in offset fashion through avertically standing support post. The baluster rail members of the stepsegments are configured to be aligned adjacent to each other and areconnected one to the other by screws. Spacer sleeves separate each ofthe step segments, whose lower support members are positioned againstthe vertical surfaces of the sleeves. Alternate stacking of the sleevesand step segments and connection of the baluster rail members produces asturdy staircase structure which also includes an upper landing member.The relatively lightweight nature of the components of the kit makeassembly easy and, by simply removing the screw connections betweenbaluster rail members, a step segment or entire section of the staircasemade up of several step segments can be rotated around the verticalsupport post to alter the configuration of the staircase.

Novel features which are considered as characteristic of the inventionare set forth in particular in the appended claims. The inventionitself, however, both as to its design, construction and use, togetherwith the additional features and advantages thereof, are best understoodupon review of the following detailed description with reference to theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a completed spiral staircase assembled withthe spiral staircase kit of the present invention.

FIG. 2 shows the beginning stages of assembly of the spiral staircasekit of the present invention.

FIG. 3 shows the continuing process of assembly of the spiral staircasekit of the present invention.

FIG. 4 is a top view of a step of the spiral stairway kit of the presentinvention.

FIG. 5 is an elevation view of a step of the spiral staircase kit of thepresent invention.

FIG. 6 is a bottom view of a step of the spiral staircase kit of thepresent invention.

FIG. 7 is an end view of a spacer sleeve of the spiral staircase kit ofthe present invention.

FIG. 8 is an elevation view of a spacer sleeve of the spiral staircasekit of the present invention.

FIG. 9 is a top view of the landing member of the spiral staircase ofthe present invention.

FIG. 10 is an elevation view of the foot member of the spiral staircaseof the present invention.

FIG. 11 is a top view of the foot member of the spiral staircase of thepresent invention.

FIG. 12 is a partial top view of a section of the assembled spiralstaircase of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows spiral staircase 1 assembled from the spiral staircase kitof the present invention. The spiral staircase kit itself compriseselongated support post 2 configured to be vertically standing betweenfloor spaces to be connected. Support post 2 is configured to be mountedwithin a plurality of uniquely designed staircase step segments. Eachstep segment, using step segment 4 as a representative example shown inFIGS. 2 and 10, comprises a step section having an upper step surface 12and a donut-shaped inboard end section 13 formed with opening 14. (SeeFIGS. 4-6). End section 13 is shown completely enclosing opening 14. Analternate design could have a part of end section 13 open, substantiallyenclosing opening 14. Two lateral support members 15 and 16 extend downfrom step surface 12. Vertical rear surfaces 17 and 18 of supportmembers 15 and 16 extend perpendicularly to step surface 12. Stepsegment 4 also comprises upstanding baluster rail member 40, connectedby two or more screws 52 to step surface 12, as shown in FIG. 2. Stepsegment 4, as a single unit, is slid onto support post 2 via opening 14,or only the step section of the segment, shown in FIGS. 4-6, can be slidover the support post and baluster rail member 40 can be secured to stepsurface 12 thereafter.

As seen in FIGS. 7 and 8, representative spacer sleeve 20 is cylindricalin configuration and comprises through opening 21. FIG. 9 showshorizontal staircase landing member 32, which comprises a flat landing33 and donut-shaped end section 34 with opening 35. Staircase footmember 36, shown in FIG. 11, has a center through opening 38 and ahorizontal lower surface for placement on the floor on which staircase 1is to be placed.

The spiral staircase kit of the present invention is assembled byinitially positioning the lowermost end of support post 2 within opening38 of foot member 36. Opening 21 of sleeve 20 is positioned over post 2and then sleeve 20, as shown in FIG. 2, is slid down along support post2. Opening 14 of end section 13 of step segment 4 is then positionedover support post 2 and the step segment, optimally with baluster railmember 40 attached, is slid down onto sleeve 20. The diameters ofopening 38 of foot member 36, opening 14 of end section 13, and opening21 of sleeve 20 are larger than the outside diameter of support post 2,thus allowing foot member 36, step segment 4 and sleeve 20 to bepositioned over and easily slid down support post 2. The diameter ofopening 14 is smaller than the diameter of opening 21 to allow endsection 13 of step segment 4 to rest on sleeve 20. The openings ofsleeves 22-28 and step segments 5-11 are similarly configured.

Once step segment 4 is placed in the proper position on sleeve 20, theforce of gravity compels the step segment against the sleeve, resultingin end section 13 resting flush on top of sleeve 20 and verticalsurfaces 17 and 18 of lateral support members 15 and 16 resting flushagainst and in adjacent contact with a lateral surface of sleeve 20.Step surface 12 thus becomes fixedly positioned in a transverse plane inrelation to support post 2.

As previously described, since the diameters of the openings of all thesleeves and steps used in the present invention are the same, once theinitial sleeve 20 and step segment 4 are in place, as seen in FIG. 2,sleeve 22 is positioned over support post 2 and slid down the post andpositioned in offset fashion to rest on end section 13 of step segment4. See FIG. 3. End section of step segment 5, with its baluster railmember 42 and corresponding opening, is then positioned over supportpost 2 and slid down the post such that it rests on sleeve 22. Onceagain, the vertical surfaces of the lateral support members of stepsegment 5 rest against a lateral surface of sleeve 22 to maintain it inplace in its offset position. The weight of sleeve 22 and newly addedstep segment 5 assists in maintaining step segment 4 in its originallyassembled position.

As can be readily appreciated, sleeves 23-28 and the remaining sleevesto be used for the staircase system and the end sections of stepsegments 5-11 and the remaining step segments to be used, each withtheir respective baluster members (all sleeves and step segments areseen in FIG. 1, showing fully assembled staircase 1), are thenpositioned, in sequence, over support post 2 and slid, alternately, downthe post, each step segment being appropriately offset to form thespiral stairway around the support post. The weight and positioning ofstep segment upon sleeve upon step segment assists in ensuring that thestep segments of the present invention are maintained around and againstsupport post 2. However, since none of the step segments are fastened tosupport post 2 or to any of the space sleeves, each step segment is freeto rotate, at its inboard end section, around the support post, absentother connection. Secure connection of step segment is accomplished bybaluster rail members as described hereinafter. After all step segmentshave been placed, sleeve 30 is positioned over and slid onto supportpost 2. Opening 35 of end section 34 of landing member 32, withupstanding baluster rail 48, is then centered over support post 2 andthe landing member is slid down onto and positioned on the post, itsside surface resting against sleeve 30, to maintain the landing inplace.

Placing step segments 4-11, the remaining step segments (not shown inFIG. 3, but shown in FIG. 1), and landing member 32 in the appropriatespiraled, offset positions will cause baluster rail members 40, 42, and44 and the other baluster rail members on the remaining step segments tobe aligned to form a continuous rail, as seen in FIG. 1. For instance,as best seen in FIG. 12, baluster rail member 40 of step segment 4 willbe adjacently aligned with baluster rail member 42 of step segment 5;baluster rail member 42 of step segment 5 will be adjacently alignedwith baluster rail member 44 of step segment 6, baluster rail member 44of step segment 6 will be adjacently aligned with baluster rail member46 of step segment 7, etc. Adjacent baluster rail members are thenconnected by two or more screws 54, to rigidly secure the step segmentstogether. This ties all components together and rigidly securesstaircase 1 in place. Lower step support 29 piece is added to provideadditional support and stability between lowest step segment 4 and thefloor surface.

Should the configuration of spiral staircase 1 need to be altered, forinstance if large furniture is to be transported up the staircase,screws 54 between the effected, adjacently aligned step segments caneasily be removed, thus separating step segments or entire sections ofthe staircase made up of several step segments from each other, allowingthe step segments to be rotated around support post 2 to alter theconfiguration of the staircase.

It is contemplated that the steps of the present invention, as well asthe handrail and balusters, can be configured and fabricated to a designof choice. While the components of the spiral staircase kit can be madeof metal or any other sturdy material, it has been found that the use oflightweight wood has several advantages. It is easy to work with and canbe fashioned into many different design configurations. The support postand spacer sleeves can be made of plastic or similar PVC type material.Use of such material as components guarantees the lightweight nature ofthe individual components and the ease of transportability and ultimateassembly and of separability and rotation of the step segments.

It is thus seen that the spiral staircase kit of the present inventionresults in a spiral staircase which can be assembled to connect adjacentfloors in virtually any building space. It is lightweight for assemblypurposes and results in a rugged and sturdy staircase unit, whose veryweight assists in the stability and rigidity of the staircase. Thestaircase components are relatively inexpensive and simple tomanufacture and are easily assembled and presents an attractive, as wellas functional spiral staircase system. The staircase also has thesignificant added advantage of flexibility in permitting easy alteringof its configuration to accommodate space limitations.

Certain novel features and components of this invention are disclosed indetail in order to make the invention clear in at least one formthereof. However, it is to be clearly understood that the invention asdisclosed is not necessarily limited to the exact form and details asdisclosed, since it is apparent that various modifications and changesmay be made without departing from the spirit of the invention.

1. A spiral staircase kit comprising: an elongated support post; aplurality of step segments, each step segment comprising: (a) a stepsurface having a transversly extending length; (b) means for rotatablymounting the step segment substantially around the support post; (c)support means extending downward from and the full transverse length ofthe step surface to maintain the step segment in a substantiallytransverse plane in relation to the support post when the step segmentis mounted on the support post; and (d) a baluster rail member to beconnected to the step surface, said member having attachment means forconnecting the baluster rail member to the step surface; a plurality ofspacer means to be positioned around the support post, one of theplurality of spacer means being located between each of the stepsegments for supporting the step segments when the step segments aremounted around the support post, each of the step segment support meansbeing in adjacent contact with one of the spacer means when the stepsegments are mounted around the support post; and second attachmentmeans for connecting a baluster rail member of one of the step segmentsto an adjacently aligned baluster rail member of another step segment,whereby when the second attachment means connects all the adjacentlyaligned baluster rail members of each step segment to each other, thestep segments are rigidly secured around the support post to form aspiral staircase.
 2. The spiral staircase kit as in claim 1 wherein themeans for rotatably mounting comprises an inboard end section withopening means to receive the support post.
 3. The spiral staircase kitas in claim 1 wherein the support means comprises at least one supportmember extending below the step surface.
 4. The spiral staircase kit asin claim 3 wherein the means for rotatably mounting comprises an inboardend section with opening means for receiving the support post.
 5. Thespiral staircase kit as in claim 1 wherein the plurality of spacer meanscomprises a plurality of cylindrical sleeves which substantiallycircumscribe the support post.
 6. The spiral staircase kit as in claim 1further comprising a landing member with means for mounting the landingmember substantially around the post.
 7. The spiral staircase kit as inclaim 1 wherein the second attachment means comprises removeable screwmembers.
 8. A spiral staircase kit comprising: an elongated supportpost; a plurality of unitary steps, each unitary step comprising a stepsurface having a transversly extending length, means for rotatablymounting the step substantially around the support post, and supportmeans extending downwardly from and the full transverse length of thestep surface to maintain the step surface in a substantially transverseplane in relation to the support post when the step is mounted on thepost; a plurality of spacer means to be positioned around the supportpost, one of the plurality of spacer means to be located between each ofthe steps for supporting the steps when they are mounted around thesupport post, each of the support means being in adjacent contact withone of the spacer means when the steps are mounted around the supportpost; and a baluster rail member to be secured to the step surface ofeach of the plurality of steps, each baluster rail member having firstattachment means for connecting the baluster rail member to a stepsurface and second attachment means for connecting a baluster railmember to an adjacently aligned baluster rail member, whereby when thefirst and second attachment means are connected, the steps are rigidlysecured around the support post and when the first attachment means areconnected and the second attachment means are not connected, each step,with its attached baluster rail member, is free to rotate about thesupport post.
 9. The spiral staircase kit as in claim 8 wherein themeans for rotatably mounting comprises an inboard end section withopening means to receive the support post.
 10. The spiral staircase kitas in claim 8 wherein the support means comprises at least one supportmember extending below the step surface.
 11. The spiral staircase kit asin claim 10 wherein the means for rotatably mounting comprises aninboard end section with opening means for receiving the support post.12. The spiral staircase kit as in claim 8 wherein the plurality ofspacer means comprises a plurality of cylindrical sleeves whichsubstantially circumscribe the support post.
 13. The spiral staircasekit as in claim 8 further comprising a landing member with means formounting the landing member substantially around the post.
 14. Thespiral staircase kit as in claim 1 wherein the second attachment meanscomprises removeable screw members.
 15. The spiral staircase comprising:an elongated support post; a plurality of step segments, each stepsegment comprising: (a) a step surface having a transversly extendinglength; (b) means for rotatably mounting the step segment substantiallyaround the support post; (c) support means extending downwardly from andthe full transverse length of the step surface to maintain the stepsegment in a substantially transverse plane in relation to the supportpost when the step segment is mounted on the support post; and (d) abaluster rail member connected to the step surface, said member havingattachment means for connecting the member to the step surface; aplurality of spacer means positioned around the support post, one of theplurality of spacer means located between each of the step segments forsupporting the step segments when the step segments are mounted aroundthe support post, each of the step segment support means being inadjacent contact with one of the spacer means when the step segments aremounted around the support post; and second attachment means forconnecting a baluster rail member of one of the step segments to anadjacently aligned baluster rail member of another step segment, wherebywhen the second attachment means connects all the adjacently alignedbaluster rail members of each step segment to each other, the stepsegments are rigidly secured around the support post and when the secondattachment means are not connected between baluster rail members, stepsegments are free to rotate about the support post.
 16. The spiralstaircase kit as in claim 15 wherein the means for rotatably mountingcomprises an inboard end section with opening means to receive thesupport post.
 17. The spiral staircase kit as in claim 15 wherein thesupport means comprises at least one support member extending below thestep surface.
 18. The spiral staircase kit as in claim 15 wherein theplurality of spacer means comprises a plurality of cylindrical sleeveswhich substantially circumscribe the support post.
 19. The spiralstaircase kit as in claim 15 further comprising a landing member withmeans for mounting the landing member substantially around the post. 20.The spiral staircase kit as in claim 15 wherein the second attachmentmeans comprises removeable screw members.